Reheatable food product

ABSTRACT

A method for producing a reheatable food product includes mixing butter, maltodextrin and breadcrumbs so as to form a butter mixture, obtaining a first slice of bread and a second slice of bread, spreading the butter mixture onto a first surface of the first slice of bread and a first surface of the second slice of bread, applying 5 g to 70 g of a filling to the second surface of the first slice of bread, positioning the second slice of bread on the filling such that the second surface of the second slice of bread is adjacent thereto to form the food product, grilling the food product until the first surfaces are golden brown, and compressing the food product to a thickness of 0.56 inches to 0.75 inches while grilling, freezing the food product to a frozen state, reheating the food product.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims the benefit of U.S.Pat. Application Serial No. 16/727,172, filed Dec. 26, 2019, which ishereby incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present disclosure relates generally to reheatable food items andmethods for producing such reheatable food items. Specifically, thepresent disclosure relates to food items containing a filling thereinthat are reheatable in at least one of a toaster and a microwave from arefrigerated or frozen state.

BACKGROUND OF THE INVENTION

Food products that are prepared using a toaster or microwave areincreasingly popular due to their convenience and quick cook times.Often, these food products contain a filling therein and are reheatedfrom a frozen or refrigerated state. When reheating these food products,consumers enjoy a reheated food product that has the same taste andeating characteristics as a fresh product that does not require atoaster or microwave for reheating.

SUMMARY OF THE INVENTION

The summary is a high-level overview of various aspects of the inventionand introduces some of the concepts that are further detailed in theDetailed Description section below. This summary is not intended toidentify key or essential features of the claimed subject matter, nor isit intended to be used in isolation to determine the scope of theclaimed subject matter. The subject matter should be understood byreference to the appropriate portions of the entire specification, anyor all drawings, and each claim.

Embodiments of the present disclosure relate to a method for producing areheatable food product. The method includes mixing butter and at leastone dry ingredient so as to form a butter mixture. The butter mixtureuses fat from a dairy source. The method also includes obtaining a firstslice of bread and a second slice of bread. Each of the first slice ofbread and the second slice of bread includes a first surface and asecond, opposing surface. The method also includes spreading the buttermixture onto the first surface of the first slice of bread and the firstsurface of the second slice of bread. The butter mixture is spread toedges of the first surface of the first slice of bread and the firstsurface of the second slice of bread. The method also includes applying5 g to 70 g of a filling to the second surface of the first slice ofbread. The method also includes positioning the second slice of bread onthe filling such that the second surface of the second slice of bread isadjacent thereto to form the food product. The method also includesgrilling the food product until the first surfaces are golden brown. Themethod also includes compressing the food product to 0.6 inches to 1inch while grilling. The method also includes freezing the food productto a frozen state. The method also includes reheating the food product.The food product does not consist essentially of butter on either thesecond surface of the first slice of bread or the second surface of thesecond slice of bread. The food product does not consist essentially ofa sealant on either the second surface of the first slice of bread orthe second surface of the second slice of bread.

In some embodiments, the at least one dry ingredient includesmaltodextrin and breadcrumbs.

In some embodiments, the reheating includes toasting the food productfor at least one cycle.

In some embodiments, the reheating includes microwaving the food productfor 15 to 60 seconds.

In some embodiments, the reheating includes microwaving the food productfor 15 to 60 seconds and toasting the food product.

In some embodiments, the butter mixture includes 60-90% of the saltedbutter by weight, 0.1-15% of the maltodextrin by weight and 10-20% ofthe breadcrumbs by weight.

In some embodiments, the mixing of the butter mixture includes mixingthe maltodextrin and the breadcrumbs to form a dry blend and mixing thedry blend with the butter for 3 to 5 minutes.

In some embodiments, the butter mixture is heated to a temperature of65° F. to 90° F.

In some embodiments, the food product is grilled at a temperature of250° F. to 540° F. for 25 to 45 seconds.

In some embodiments, the food product is grilled on a clamshell grill, abelt grill, a panini press or a flat top grill.

In some embodiments, the filling comprises at least one of cheese, meat,egg, vegetable, sauce, spreads, fruit and combinations thereof.

In some embodiments, the method further includes wrapping the foodproduct in a polyethylene plastic flow wrap or any food-grade wrapperimpervious to moisture.

In some embodiments, the food product is cooled to a temperature of 60°F. to 140° F. prior to wrapping.

In some embodiments, the food product is frozen to a temperature of -25°F. to 25° F. prior to wrapping.

In some embodiments, the food product is frozen to a temperature of -25°F. to 25° F. after to wrapping.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the disclosure and are incorporated in and constitute apart of this specification, illustrate embodiments, and together withthe description serve to explain the principles of the presentdisclosure.

FIG. 1 is a perspective view of a butter mixture, according toembodiments of the present disclosure;

FIG. 2 is a top view of a first slice of bread and a second slice ofbread, according to embodiments of the present disclosure;

FIG. 3 is a top view of the first slice of bread with the fillingapplied to a second major surface thereof, according to embodiments ofthe present disclosure;

FIG. 4 is a cross-sectional view of a completed food product, accordingto embodiments of the present disclosure;

FIG. 5 is a diagrammatic perspective view of a grilling apparatus withthe food product placed on a bottom grilling plate thereof, according toembodiments of the present disclosure; and

FIG. 6 is a perspective view of the food product in a wrapper.

DETAILED DESCRIPTION

Persons skilled in the art will readily appreciate that various aspectsof the present disclosure can be realized by any number of methods andapparatus configured to perform the intended functions. It should alsobe noted that the accompanying figures referred to herein are notnecessarily drawn to scale but may be exaggerated to illustrate variousaspects of the present disclosure, and in that regard, the figuresshould not be construed as limiting.

Described herein are methods for producing a reheatable food product.Specifically, the present disclosure relates to methods for producing areheatable food product in at least one of a toaster and a microwave. Insome embodiments, the reheatable food product includes a fillingtherein. In some embodiments, the reheatable food product is reheatedfrom a refrigerated or frozen state. In an exemplary embodiment, thereheatable food product is a sandwich.

FIG. 1 depicts a first step of the method of producing the food product10. In some embodiments, the method begins by forming a butter mixture100. In some embodiments, the butter mixture 100 includes butter 102 andat least one dry ingredient. In some embodiments, the butter mixture 100includes maltodextrin 104 and breadcrumbs 106 as dry ingredients. Otheringredients that may be included in the butter mixture 100 include, butare not limited to, sugar, egg, spices, oils, non-bread crumbs, nutbutters, cheese, or a combination thereof. In some embodiments, thebutter mixture 100 is formed by blending or mixing the maltodextrin 104and the breadcrumbs 106 until well combined to form a dry mixture. Thedry mixture is then combined with the butter 102 that has been warmed toroom temperature. The dry mixture and the room temperature butter are,in some embodiments, mixed together at low speed for 3 to 5 minutes,until the dry blend is completely incorporated into the butter 102,forming the butter mixture 100.

In some embodiments, the butter mixture 100 includes 60-90% by weightbutter. In other embodiments, the butter mixture 100 includes 60-85% byweight butter. In other embodiments, the butter mixture 100 includes60-80% by weight butter. In other embodiments, the butter mixture 100includes 60-75% by weight butter. In other embodiments, the buttermixture 100 includes 60-70% by weight butter. In other embodiments, thebutter mixture 100 includes 60-65% by weight butter.

In some embodiments, the butter mixture 100 includes 65-90% by weightbutter. In other embodiments, the butter mixture 100 includes 70-90% byweight butter. In other embodiments, the butter mixture 100 includes75-90% by weight butter. In other embodiments, the butter mixture 100includes 80-90% by weight butter. In other embodiments, the buttermixture 100 includes 85-90% by weight butter.

In some embodiments, the butter mixture 100 includes 65-85% by weightbutter. In other embodiments, the butter mixture 100 includes 65-80% byweight butter. In other embodiments, the butter mixture 100 includes70-80% by weight butter. In other embodiments, the butter mixture 100includes 70-75% by weight butter. In other embodiments, the buttermixture 100 includes 75-85% by weight butter. In other embodiments, thebutter mixture 100 includes 80-85% by weight butter.

In some embodiments, the butter mixture 100 includes 10-40% by weightdry ingredients. In other embodiments, the butter mixture 100 includes10-35% by weight dry ingredients. In other embodiments, the buttermixture 100 includes 10-30% by weight dry ingredients. In otherembodiments, the butter mixture 100 includes 10-25% by weight dryingredients. In other embodiments, the butter mixture 100 includes10-20% by weight dry ingredients. In other embodiments, the buttermixture 100 includes 10-15% by weight dry ingredients.

In some embodiments, the butter mixture 100 includes 15-40% by weightdry ingredients. In other embodiments, the butter mixture 100 includes20-40% by weight dry ingredients. In other embodiments, the buttermixture 100 includes 25-40% by weight dry ingredients. In otherembodiments, the butter mixture 100 includes 30-40% by weight dryingredients. In other embodiments, the butter mixture 100 includes35-40% by weight dry ingredients.

In some embodiments, the butter mixture 100 includes 15-35% by weightdry ingredients. In other embodiments, the butter mixture 100 includes15-30% by weight dry ingredients. In other embodiments, the buttermixture 100 includes 15-25% by weight dry ingredients. In otherembodiments, the butter mixture 100 includes 20-30% by weight dryingredients. In other embodiments, the butter mixture 100 includes25-35% by weight dry ingredients. In other embodiments, the buttermixture 100 includes 30-35% by weight dry ingredients.

In some embodiments, the dry ingredients include maltodextrin andbreadcrumbs. In some embodiments, the butter mixture 100 includes0.1-15% by weight maltodextrin. In other embodiments, the butter mixture100 includes 0.5-15% by weight maltodextrin. In other embodiments, thebutter mixture 100 includes 1-15% by weight maltodextrin. In otherembodiments, the butter mixture 100 includes 5-15% by weightmaltodextrin. In other embodiments, the butter mixture 100 includes10-15% by weight maltodextrin.

In some embodiments, the butter mixture 100 includes 0.1-10% by weightmaltodextrin. In other embodiments, the butter mixture 100 includes0.1-5% by weight maltodextrin. In other embodiments, the butter mixture100 includes 0.1-1% by weight maltodextrin. In other embodiments, thebutter mixture 100 includes 0.1-0.5% by weight maltodextrin.

In some embodiments, the butter mixture 100 includes 0.5-10% by weightmaltodextrin. In other embodiments, the butter mixture 100 includes 1-5%by weight maltodextrin. In other embodiments, the butter mixture 100includes 1-10% by weight maltodextrin. In other embodiments, the buttermixture 100 includes 5-10% by weight maltodextrin. In other embodiments,the butter mixture 100 includes 0.5-5% by weight maltodextrin. In otherembodiments, the butter mixture 100 includes 0.5-1% by weightmaltodextrin.

In some embodiments, the butter mixture 100 includes 10-20% breadcrumbs.In other embodiments, the butter mixture 100 includes 12-20%breadcrumbs. In other embodiments, the butter mixture 100 includes14-20% breadcrumbs. In other embodiments, the butter mixture 100includes 16-20% breadcrumbs. In other embodiments, the butter mixture100 includes 18-20% breadcrumbs.

In some embodiments, the butter mixture 100 includes 10-18% breadcrumbs.In other embodiments, the butter mixture 100 includes 10-16%breadcrumbs. In other embodiments, the butter mixture 100 includes10-14% breadcrumbs. In other embodiments, the butter mixture 100includes 10-12% breadcrumbs.

In some embodiments, the butter mixture 100 includes 12-18% breadcrumbs.In other embodiments, the butter mixture 100 includes 12-16%breadcrumbs. In other embodiments, the butter mixture 100 includes12-14% breadcrumbs. In other embodiments, the butter mixture 100includes 14-18% breadcrumbs. In other embodiments, the butter mixture100 includes 14-16% breadcrumbs. In other embodiments, the buttermixture 100 includes 16-18% breadcrumbs.

In some embodiments, the butter 102 is fat from a dairy source. In someembodiments, the butter 102 is salted.

In some embodiments, the breadcrumbs 106 are toasted.

In some embodiments, once the butter mixture 100 is formed, it is heldat a temperature of from 65° F. to 90° F. In other embodiments, thebutter mixture 100 is held at a temperature of 65° F. to 85° F. In otherembodiments, the butter mixture 100 is held at a temperature of 65° F.to 80° F. In other embodiments, the butter mixture 100 is held at atemperature of 65° F. to 75° F. In other embodiments, the butter mixture100 is held at a temperature of 65° F. to 70° F.

In some embodiments, the butter mixture 100 is held at a temperature of70° F. to 90° F. In other embodiments, the butter mixture 100 is held ata temperature of 75° F. to 90° F. In other embodiments, the buttermixture 100 is held at a temperature of 80° F. to 90° F. In otherembodiments, the butter mixture 100 is held at a temperature of 85° F.to 90° F.

In some embodiments, the butter mixture 100 is held at a temperature of70° F. to 80° F. In other embodiments, the butter mixture 100 is held ata temperature of 75° F. to 80° F. In other embodiments, the buttermixture 100 is held at a temperature of 80° F. to 85° F. In otherembodiments, the butter mixture 100 is held at a temperature of 75° F.to 85° F.

Turning to FIG. 2 , a first slice of bread 108 and a second slice ofbread 110 are obtained. Each of the first slice of bread 108 and thesecond slice of bread 110 includes a first major surface 112 and anopposing second major surface 114. In some embodiments, each of thefirst slice of bread 108 and the second slice of bread 110 is 4 incheslong by 4 inches wide. In some embodiments, however, the length andwidth of the bread can range from 3 in to 4.5 in. In other embodiments,the length and width of the bread can range from 3.4 in to 4.5 in. Inother embodiments, the length and width of the bread can range from 3.8in to 4.5 in. In other embodiments, the length and width of the breadcan range from 4.2 in to 4.5 in.

In some embodiments, however, the length and width of the bread canrange from 3 in to 4.2 in. In other embodiments, the length and width ofthe bread can range from 3 in to 4 in. In other embodiments, the lengthand width of the bread can range from 3 in to 3.8 in. In otherembodiments, the length and width of the bread can range from 3 in to3.4 in.

In some embodiments, however, the length and width of the bread canrange from 3.5 in to 4 in. In other embodiments, the length and width ofthe bread can range from 3.6 in to 4.2 in. In other embodiments, thelength and width of the bread can range from 3.8 in to 3.9 in. In otherembodiments, the length and width of the bread can range from 4 in to4.4 in. In other embodiments, the length and width of the bread canrange from 3.2 in to 4.2 in.

In some embodiments, the first slice of bread 108 and the second sliceof bread 110 are white bread. However, in other embodiments, any type ofbread may be used including, but not limited to, bagels, tortillas,naan, etc.

Once the first slice of bread 108 and second slice of bread 110 areobtained, the butter mixture 100 is applied to the first major surface112 of each of the first slice of bread 108 and the second slice ofbread 110, as depicted in FIG. 2 . In some embodiments, the buttermixture 100 is spread to each edge 116 of the first major surface 112,ensuring that the entire first major surface 112 is coated, as depictedin FIG. 2 .

In some embodiments, 8 g to 12 g of the butter mixture 100 is applied tothe first major surface 112 of each slice of bread. In otherembodiments, 9 g to 12 g of the butter mixture 100 is applied to thefirst major surface 112. In other embodiments, 10 g to 12 g of thebutter mixture 100 is applied to the first major surface 112. In otherembodiments, 11 g to 12 g of the butter mixture 100 is applied to thefirst major surface 112.

In some embodiments, 8 g to 11 g of the butter mixture 100 is applied tothe first major surface 112 of each slice of bread. In otherembodiments, 8 g to 10 g of the butter mixture 100 is applied to thefirst major surface 112. In other embodiments, 8 g to 9 g of the buttermixture 100 is applied to the first major surface 112.

In some embodiments, 9 g to 11 g of the butter mixture 100 is applied tothe first major surface 112 of each slice of bread. In otherembodiments, 10 g to 11 g of the butter mixture 100 is applied to thefirst major surface 112. In other embodiments, 9 g to 10 g of the buttermixture 100 is applied to the first major surface 112.

In some embodiments, the butter mixture 100 is applied to the first andsecond slices of bread 108, 110 at the same temperatures provided abovewith respect to the holding of the butter mixture 100.

In some embodiments, no butter is applied to either the second majorsurface 114 of the first slice of bread 108 or the second major surface114 of the second slice of bread 110. In some embodiments, the foodproduct 10 does not consist essentially of butter on either the secondsurface major surface 114 of the first slice of bread 108 or the secondsurface 114 of the second slice of bread 110.

As depicted in FIG. 4 , a filling 118 is then applied to the first sliceof bread 108. To apply the filling 118, the first slice of bread 108 isflipped over so that the second major surface 114 thereof, which doesnot have the butter mixture 100 thereon, is exposed. The filling 118 isthen, in some embodiments, deposited onto the second major surface 114of the first slice of bread 108.

In some embodiments, the filling 118 comprises: cheese (hard, medium,soft, process, sliced, shredded), meat (cured, pre-cooked, extended,chopped, sliced, shredded), egg (patties, scrambled, raw), vegetable(raw, cooked, pickled), sauce (pesto, marinara, barbeque, cheese,ketchup, mustard, mayonnaise, Worcestershire, salad dressing, chocolatesauce, relish), spreads (cream cheese, nut butters, jellies, jams,marshmallow crème, hot fudge), fruit (raw, cooked, as jelly/jam/piefilling), and combinations thereof. In the exemplary embodiment of FIG.4 , pasteurized process cheese is applied to the bread.

In some embodiments, 5 g to 70 g of filling 118 is applied to the firstslice of bread 108. In other embodiments, 5 g to 60 g of filling 118 isapplied to the first slice of bread 108. In other embodiments, 5 g to 50g of filling 118 is applied to the first slice of bread 108. In otherembodiments, 5 g to 40 g of filling 118 is applied to the first slice ofbread 108. In other embodiments, 5 g to 30 g of filling 118 is appliedto the first slice of bread 108. In other embodiments, 5 g to 20 g offilling 118 is applied to the first slice of bread 108. In otherembodiments, 5 g to 10 g of filling 118 is applied to the first slice ofbread 108.

In some embodiments, 10 g to 70 g of filling 118 is applied to the firstslice of bread 108. In other embodiments, 20 g to 70 g of filling 118 isapplied to the first slice of bread 108. In other embodiments, 30 g to70 g of filling 118 is applied to the first slice of bread 108. In otherembodiments, 40 g to 70 g of filling 118 is applied to the first sliceof bread 108. In other embodiments, 50 g to 70 g of filling 118 isapplied to the first slice of bread 108. In other embodiments, 60 g to70 g of filling 118 is applied to the first slice of bread 108.

In some embodiments, 10 g to 60 g of filling 118 is applied to the firstslice of bread 108. In other embodiments, 20 g to 60 g of filling 118 isapplied to the first slice of bread 108. In other embodiments, 30 g to50 g of filling 118 is applied to the first slice of bread 108. In otherembodiments, 30 g to 40 g of filling 118 is applied to the first sliceof bread 108. In other embodiments, 50 g to 60 g of filling 118 isapplied to the first slice of bread 108. In other embodiments, 40 g to50 g of filling 118 is applied to the first slice of bread 108. In otherembodiments, 40 g to 60 g of filling 118 is applied to the first sliceof bread 108.

After the filling 118 is applied to the first slice of bread 108, thefood product 10 is formed by placing the second slice of bread 110 overthe filling 118 such that the second major surface 114 of the secondslice of bread 110 is adjacent to the filling 118, as depicted in FIG. 5. Thus, both exterior surfaces of the completed food product 10 arecoated with the butter mixture 100.

Upon closing, the food product 10 is grilled on a grilling apparatus120, as depicted in FIG. 6 . In some embodiments, the grilling apparatus120 includes a top grill plate 122 having a top grill surface 124 and abottom grill plate 126 having a bottom grill surface 128. In someembodiments, the grilling apparatus 120 is configured to compress thefood product 10. In some embodiments, the grilling apparatus 120 is aclamshell grill. However, in other embodiments, any type of grill may beused including, but not limited to, a belt grill, a panini press, a flattop grill and any other top and bottom gilling plate system that bothcompresses and heats both major surfaces of a food product 10.

In some embodiments, the grilling apparatus 120 is preheated until boththe top and bottom grilling plates 122, 126 reach a temperature of 425°F. Although the grilling apparatus 120 of the current embodiment isheated to 540° F., in other embodiments, the grilling apparatus 120 isheated to any temperature from 250° F. to 540° F. In other embodiments,the grilling apparatus 120 is heated to a temperature of 250° F. to 500°F. In other embodiments, the grilling apparatus 120 is heated to atemperature of 250° F. to 450° F. In other embodiments, the grillingapparatus 120 is heated to a temperature of 250° F. to 400° F. In otherembodiments, the grilling apparatus 120 is heated to a temperature of250° F. to 350° F. In other embodiments, the grilling apparatus 120 isheated to a temperature of 250° F. to 300° F.

In other embodiments, the grilling apparatus 120 is heated to atemperature of 300° F. to 540° F. In other embodiments, the grillingapparatus 120 is heated to a temperature of 350° F. to 540° F. In otherembodiments, the grilling apparatus 120 is heated to a temperature of400° F. to 540° F. In other embodiments, the grilling apparatus 120 isheated to a temperature of 450° F. to 540° F. In other embodiments, thegrilling apparatus 120 is heated to a temperature of 500° F. to 540° F.

In other embodiments, the grilling apparatus 120 is heated to atemperature of 300° F. to 350° F. In other embodiments, the grillingapparatus 120 is heated to a temperature of 300° F. to 400° F. In otherembodiments, the grilling apparatus 120 is heated to a temperature of300° F. to 450° F. In other embodiments, the grilling apparatus 120 isheated to a temperature of 300° F. to 500° F. In other embodiments, thegrilling apparatus 120 is heated to a temperature of 350° F. to 400° F.In other embodiments, the grilling apparatus 120 is heated to atemperature of 350° F. to 450° F. In other embodiments, the grillingapparatus 120 is heated to a temperature of 350° F. to 500° F. In otherembodiments, the grilling apparatus 120 is heated to a temperature of400° F. to 450° F. In other embodiments, the grilling apparatus 120 isheated to a temperature of 400° F. to 500° F. In other embodiments, thegrilling apparatus 120 is heated to a temperature of 450° F. to 500° F.

After the grilling apparatus 120 has been preheated, the food product 10is placed on the bottom grill surface 128 of the bottom grill plate 126.The top grill plate 122 is then positioned onto the food product 10 inpreparation for grilling. In some embodiments, the food product 10 issimultaneously grilled and compressed to a grilling apparatuscompression thickness. Compressing the food product 10 ensures that thefood product 10 stays intact throughout the production thereof andprevents filling from spilling out of the sides thereof. In someembodiments, the top and bottom grill plates are set to a platecompression of 0.6 in to 1 in such. In other embodiments, the grillplates are set to a plate compression of 0.7 in to 1 in. In otherembodiments, the grill plates are set to a plate compression of 0.8 into 1 in. In other embodiments, the grill plates are set to a platecompression of 0.9 in to 1 in.

In some embodiments, the grill plates are set to a plate compression of0.6 in to 0.9 in. In other embodiments, the grill plates are set to aplate compression of 0.6 in to 0.8 in. In other embodiments, the grillplates are set to a plate compression of 0.6 in to 0.7 in.

In some embodiments, the grill plates are set to a plate compression of0.7 in to 0.9 in. In other embodiments, the grill plates are set to aplate compression of 0.7 in to 0.8 in. In other embodiments, the grillplates are set to a plate compression of 0.8 in to 0.9 in.

In some embodiments, the food product 10 does not include a sealant oneither the second major surface of the first slice of bread or thesecond major surface of the second slice of bread. In some embodiments,the food product 10 does not consist essentially of a sealant on eitherthe second major surface of the first slice of bread or the second majorsurface of the second slice of bread.

In some embodiments, the food product 10 is grilled until golden brownfor 25 seconds to 180 seconds, depending on the temperature of thegrilling apparatus 120 and the required grilling characteristics of thefinished food product 10. For example, a higher grilling temperaturewould require a shorter grill time, while a lower grilling temperaturewould require a longer grill time. In other embodiments, the foodproduct 10 is grilled for 25 seconds to 180 seconds. In otherembodiments, the food product 10 is grilled for 25 seconds to 120seconds. In other embodiments, the food product 10 is grilled for 25seconds to 100 seconds. In other embodiments, the food product 10 isgrilled for 25 seconds to 60 seconds. In other embodiments, the foodproduct 10 is grilled for 25 seconds to 35 seconds. In otherembodiments, the food product 10 is grilled for 25 seconds to 30seconds.

In some embodiments, the food product 10 is grilled for 30 seconds to180 seconds. In other embodiments, the food product 10 is grilled for 35seconds to 180 seconds. In other embodiments, the food product 10 isgrilled for 60 seconds to 180 seconds. In other embodiments, the foodproduct 10 is grilled for 100 seconds to 180 seconds. In otherembodiments, the food product 10 is grilled for 120 seconds to 180seconds.

In some embodiments, the food product 10 is grilled for 30 seconds to120 seconds. In other embodiments, the food product 10 is grilled for 35seconds to 100 seconds. In other embodiments, the food product 10 isgrilled for 60 seconds to 120 seconds. In other embodiments, the foodproduct 10 is grilled for 120 seconds to 160 seconds. In otherembodiments, the food product 10 is grilled for 35 seconds to 45seconds.

Grilling is completed upon achieving the desired appearance and eatingcharacteristics of the food product 10. Once grilling is complete, thefood product 10 is allowed to cool to a suitable surface temperature forwrapping in preparation for freezing. In some embodiments, the foodproduct 10 is cooled to an temperature of 60° F. to 140° F. In otherembodiments, the food product 10 is cooled to a temperature of 85° F. to140° F. In other embodiments, the food product 10 is cooled to atemperature of 100° F. to 140° F. In other embodiments, the food product10 is cooled to a temperature of 115° F. to 140° F. In otherembodiments, the food product 10 is cooled to a temperature of 130° F.to 140° F.

In some embodiments, the food product 10 is cooled to an temperature of60° F. to 130° F. In other embodiments, the food product 10 is cooled toa temperature of 60° F. to 115° F. In other embodiments, the foodproduct 10 is cooled to a temperature of 60° F. to 100° F. In otherembodiments, the food product 10 is cooled to a temperature of 60° F. to85° F.

In some embodiments, the food product 10 is cooled to an temperature of60° F. to 140° F. In other embodiments, the food product 10 is cooled toa temperature of 85° F. to 140° F. In other embodiments, the foodproduct 10 is cooled to a temperature of 100° F. to 140° F. In otherembodiments, the food product 10 is cooled to a temperature of 115° F.to 140° F. In other embodiments, the food product 10 is cooled to atemperature of 130° F. to 140° F.

In some embodiments, the food product 10 is then packaged or wrapped forfreezing and storage, as depicted in FIG. 7 . In some embodiments, thefood product 10 is wrapped in a polyethylene plastic flow wrap 130. Inother embodiments, the food product 10 is wrapped in any otherfood-grade wrapper that is impervious to moisture.

Once wrapped, the food product 10 is frozen for storage prior to retailsale, and thereafter stored frozen at a consumer’s location. In someembodiments, the food product 10 is frozen to a temperature of -25° F.to 25° F. In other embodiments, the food product 10 is frozen to atemperature of -15° F. to 25° F. In other embodiments, the food product10 is frozen to a temperature of -5° F. to 25° F. In other embodiments,the food product 10 is frozen to a temperature of 0° F. to 25° F. Inother embodiments, the food product 10 is frozen to a temperature of 5°F. to 25° F. In other embodiments, the food product 10 is frozen to atemperature of 15° F. to 25° F. In other embodiments, the food product10 is frozen to a temperature of 20° F. to 25° F.

In some embodiments, the food product 10 is frozen to a temperature of-25° F. to 20° F. In other embodiments, the food product 10 is frozen toa temperature of -25° F. to 15° F. In other embodiments, the foodproduct 10 is frozen to a temperature of -25° F. to 10° F. In otherembodiments, the food product 10 is frozen to a temperature of -25° F.to 5° F. In other embodiments, the food product 10 is frozen to atemperature of -25° F. to 0° F. In other embodiments, the food product10 is frozen to a temperature of -25° F. to -5° F. In other embodiments,the food product 10 is frozen to a temperature of -25° F. to -10° F. Inother embodiments, the food product 10 is frozen to a temperature of-25° F. to -15° F.

In some embodiments, the food product 10 is frozen to a temperature of-20° F. to 20° F. In other embodiments, the food product 10 is frozen toa temperature of -15° F. to 15° F. In other embodiments, the foodproduct 10 is frozen to a temperature of -10° F. to 10° F. In otherembodiments, the food product 10 is frozen to a temperature of -55° F.to 5° F. In other embodiments, the food product 10 is frozen to atemperature of -5° F. to 0° F. In other embodiments, the food product 10is frozen to a temperature of 0° F. to 5° F. In other embodiments, thefood product 10 is frozen to a temperature of 5° F. to 20° F. In otherembodiments, the food product 10 is frozen to a temperature of 15° F. to20° F.

In some embodiments, the food product 10 is cooled to a freezingtemperature prior to wrapping. The food product 10 can be frozen to anyof the freezing temperatures described above.

When a consumer wishes to eat the food product 10, the consumer removesthe food product 10 from the wrapper. The food product 10 is thenreheated by microwaving, toasting or a combination of microwaving andtoasting. In some embodiments, the food product 10 is only toasted forone cycle at a medium or high setting. In other embodiments, the foodproduct 10 is microwaved for 30 seconds and subsequently toasted for onecycle at a medium or high setting. In other embodiments, the foodproduct 10 is toasted for more than one cycle, or as necessary to heatthe food product 10 to a degree desired by the consumer. In someembodiments, the food product 10 is microwaved for 15-60 seconds. Inother embodiments, the food product 10 is microwaved for 30-60 seconds.In other embodiments, the food product 10 is microwaved for 45-60seconds.

In some embodiments, the food product 10 is microwaved for 15-45seconds. In other embodiments, the food product 10 is microwaved for15-30 seconds. In some embodiments, the food product 10 is microwavedfor 30-45 seconds.

In some embodiments, the consumer can store the food product 10 in thefridge to bypass the microwave step.

The butter mixture 100 applied to the exterior surfaces of the foodproduct 10, as described above, provides many benefits during thegrilling, freezing and reheating steps of producing the food product 10.First, the breadcrumbs 106 improve the appearance and texture of thefood product 10 after grilling and reheating. Specifically, toastedbreadcrumbs 106 provide a crisp exterior to the product after toasting.Second, the breadcrumbs 106, along with the butter 102, when applied tothe surfaces of the slices of bread, move into and fill the pores of theslices of bread, which allows for enhanced heat transfer from theexterior of the food product 10 to the filling within the food product10. This enhanced heat transfer prevents burning or scorching of theexterior of the food product 10 prior to the inner filling being warmed.Third, the butter mixture 100 provides a lipid layer that, when cooled,prevents migration of moisture from the interior of the product to theexterior, thus preventing freezer burn during the freezing step. Fourth,the composition of the butter coating also provides product robustnesswhen undergoing multiple heating and cooling cycles, resulting in afresh-tasting product after freezing and preparation. Finally, thebreadcrumbs enhance the flavor and color of the food product 10.

Example

A blind taste test was performed comparing two reheatable grilled cheesesandwiches. A first reheatable grilled cheese sandwich was preparedaccording to the method described in the current disclosure. The secondreheatable grilled cheese sandwich was prepared according to the methoddisclosed in U.S. Pat. No. 6,858,241 to Kershman et al. Thirty studypanelists were asked thirty-four questions regarding which sandwich ofthe two sandwiches had preferred appearance, texture and taste.

The questions and response provided in Table 1.

TABLE 1 Question ‘241 Patent Sandwich Current Sandwich Evaluate both ofthe frozen sandwiches by looking at them and picking them up. Answereach question by checking the box that corresponds to your chosensandwich. 1. Which sandwich color do you prefer? 0 30 2. Which sandwichsurface appearance do you prefer? 2 28 3. When you touch the sandwiches,which sandwich’s texture do you prefer? 6 24 4. When you touch thesandwiches, which sandwich feels less greasy? 14 15 5. Which sandwichlooks less messy? 8 21 6. Which sandwich thickness do you prefer? 1 297. Which sandwich looks more appetizing? 1 29 8. Which sandwich looksmore homemade? 3 27 9. Which sandwich looks less greasy? 21 9 10. Whichsandwich would you rather serve to your family? 1 29 11. Which sandwichwould you be more likely to buy? 1 29 Evaluate both prepared sandwichesby looking at them. Do not taste them at this stage. Answer eachquestion by checking the box that corresponds to your chosen sandwich.12. Which sandwich color do you prefer? 2 28 13. Which sandwich surfaceappearance do you prefer? 4 26 14. Which sandwich looks less messy? 8 2115. Which sandwich looks more appetizing? 3 27 16. Which sandwich looksmore homemade? 7 23 17. Which sandwich looks less greasy? 22 7 18. Whichsandwich thickness do you prefer? 2 28 Evaluate both prepared sandwichesby touching them and picking them up. Do not taste them at this stage.Answer each question by checking the box that corresponds to your chosensandwich. 19. When you touch the sandwiches, which sandwich’s texture doyou prefer? 10 20 20. When you touch the sandwiches, which sandwichfeels more homemade? 7 34 21. When you touch the sandwiches, whichsandwich feels less greasy? 16 14 22. Which sandwich would you ratherserve to your family? 3 27 23. Which sandwich are you more likely tobuy? 2 28 Taste both sandwiches. Answer each question by checking thebox that corresponds to your chosen sandwich. 24. Which sandwich is lessgreasy? 21 9 25. Which sandwich has a better cheese flavor? 9 21 26.Which sandwich has a better butter flavor? 5 25 27. Which sandwich has abetter aftertaste? 8 22 28. Which sandwich is crispier? 9 21 29. Whichsandwich thickness do you prefer? 4 26 30. Which sandwich is moresatisfying? 5 25 31. Which sandwich is less messy to eat? 4 24 32. Whichsandwich tastes more homemade? 7 22 33. Which sandwich would you ratherserve to your family? 6 24 34. Which sandwich are you more likely tobuy? 6 24

As depicted in Table 1, the reheatable grilled cheese that was producedaccording to the disclosed method was overwhelmingly preferred by thestudy panelists in every characteristic. Using a significance level of0.01, the level of preference for the reheatable sandwich made accordingto the disclosed method was far below the significance level(0.000000476), denoting a very strong statistically significantdifference between the two samples presented. A statistical analysis ofthe results is provided in Table 2.

TABLE 2 t-Test Results Showing Statistical Difference Between the MeanCalculation of Two Samples 241 Patent Product Current ProductObservations 34 34 Mean of observations 6.71 23.09 Significantdifference p<0.01

The disclosure of this application has been described above bothgenerically and with regard to specific embodiments. It will be apparentto those skilled in the art that various modifications and variationscan be made in the embodiments without departing from the scope of thedisclosure. Thus, it is intended that the embodiments cover themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents.

What is claimed is:
 1. A method for producing a reheatable food product, comprising: mixing butter and at least one dry ingredient so as to form a butter mixture, wherein the butter mixture uses fat from a dairy source wherein the at least one dry ingredient comprises maltodextrin and breadcrumbs; obtaining a first slice of bread and a second slice of bread, wherein each of the first slice of bread and the second slice of bread comprises a first surface and an opposing second surface; spreading the butter mixture onto the first surface of the first slice of bread and the first surface of the second slice of bread, wherein the butter mixture is spread to edges of the first surface of the first slice of bread and the first surface of the second slice of bread; applying 5 g to 70 g of a filling to the second surface of the first slice of bread; positioning the second slice of bread on the filling such that the second surface of the second slice of bread is adjacent to the filling to form the food product; grilling the food product with the butter mixture spread on the first surface of the first slice of bread and the first surface of the second slice of bread; compressing the food product to a thickness of 0.6 inches to 1 inches while grilling; freezing the food product to a frozen state; and reheating the food product from the frozen state; wherein the food product does not include butter on either the second surface of the first slice of bread or the second surface of the second slice of bread, and wherein the food product does not consist essentially of a sealant on either the second surface of the first slice of bread or the second surface of the second slice of bread.
 2. (canceled)
 3. The method of claim 1, wherein the reheating comprises toasting the food product for at least one cycle.
 4. The method of claim 1, wherein the reheating comprises microwaving the food product for 15 to 60 seconds.
 5. The method of claim 1, wherein the reheating comprises: microwaving the food product for 15 to 60 seconds; and toasting the food product for at least one cycle.
 6. The method of claim 1, wherein the butter mixture comprises: 60-90% of the butter by weight; 0.1-15% of the maltodextrin by weight; and 10-20% of the breadcrumbs by weight.
 7. The method of claim 1, wherein mixing the butter mixture comprises: mixing the maltodextrin and the breadcrumbs to form a dry blend; and mixing the dry blend with the butter for 3 to 5 minutes, wherein the butter mixture is heated to a temperature of 65° F. to 90° F.
 8. The method of claim 1, wherein the food product is grilled at a temperature of 250° F. to 540° F. for 25 to 45 seconds.
 9. The method of claim 8, wherein the food product is grilled on a clamshell grill, a belt grill, a panini press or a flat top grill.
 10. The method of claim 1, wherein the filling comprises at least one of cheese, meat, egg, vegetable, sauce, spreads, fruit and combinations thereof.
 11. The method of claim 1, further comprising wrapping the food product in a polyethylene plastic flow wrap or food-grade wrapper impervious to moisture.
 12. The method of claim 11, wherein the food product is cooled to a temperature of 60° F. to 140° F. prior to wrapping.
 13. The method of claim 11, wherein during the freezing the food product is frozen to a temperature of -25° F. to 25° F. prior to wrapping.
 14. The method of claim 11, wherein during the freezing the food product is frozen to a temperature of -25° F. to 25° F. after wrapping. 